Refrigerating air dryer. ACT ph. EN - User s maintenance and spare parts manual 7425MUM181UL_EN_

Refrigerating air dryer ACT 20 500 1ph EN - User s maintenance and spare parts manual 7425MUM181UL_EN_2015-01

Dear Customer, thank you for choosing our product. In order to get the best performances out of this product, please read this manual carefully. To avoid incorrect operation of the equipment and possible physical risk to the operator, please read and strictly follow the instructions contained in this manual. Note, these instructions are in addition to the safety rules that apply in the country where the dryer is installed. Before packing for shipment each ACT series refrigerated air dryer undergoes a rigorous test to ensure the absence of any manufacturing faults and to demonstrate that the device can perform all the functions for which it has been designed. Once the dryer has been properly installed according to the instructions in this manual, it will be ready for use without any further adjustment. The operation is fully automatic, and the maintenance is limited to few controls and some cleaning operations, as detailed in the following chapters. This manual must be maintained available in any moment for future references and it has to be intended as inherent part of the relevant dryer. Due to the continuous technical evolution, we reserve the right to introduce any necessary change without giving previous notice. Should you experience any trouble, or for further information, please do not hesitate to contact us. 2 EN ACT 20 500 1ph

Contents 1 Identification plate 5 2 Warranty conditions 5 3 Safety rules 6 3.1 Definition of the conventional signs used in this manual 6 3.2 Warnings 7 3.3 Proper use of the dryer 7 3.4 Instructions for the use of pressure equipment according to PED directive 97/23/EC 8 4 Installation 8 4.1 Transport 8 4.2 Storage 8 4.3 Installation site 9 4.4 Installation layout 10 4.5 Correction factors 11 4.6 Connection to the compressed air system 12 4.7 Electrical connections 12 4.8 Condensate drain 12 5 Start-up 13 5.1 Preliminary operation 13 5.2 First start-up 13 5.3 Start-up and shut down 14 6 Technical data 15 6.1 Technical data ACT 20 200 1/115/60 15 6.2 Technical data ACT 125 500 1/230/60 16 7 Technical description 17 7.1 Control panel 17 7.2 Operation 17 7.3 Flow diagram 18 7.4 Refrigerating compressor 19 7.5 Condenser 19 7.6 Filter dryer 19 7.7 Capillary tube 19 7.8 Alu-Dry module 19 7.9 Hot gas by-pass valve 20 7.10 Refrigerant pressure switches LPS HPS PV 20 7.11 Safety thermo switch TS 20 7.12 Electronic instrument DMC14 21 7.12.1 How to switch on the dryer 21 7.12.2 How to switch off the dryer 21 7.12.3 How to display the operating parameters 21 7.12.4 How a service warning / alarm is displayed 21 7.12.5 How is controlled the drain solenoid valve 22 7.12.6 Operation of the failure / alarm dry contact 22 7.12.7 How to change the operating parameters SETUP menu 22 7.13 Electronic drainer (optional) 23 8 Maintenance, troubleshooting, spare parts and dismantling 24 8.1 Checks and maintenance 24 8.2 Troubleshooting 25 8.3 Spare parts 27 8.4 Maintenance operation on the refrigeration circuit 29 8.5 Dismantling of the dryer 29 9 Attachments 30 Exploded views List of components 30 Electric diagrams List of components 30 ACT 20 500 1ph 3 EN

Pos: 1 /Beko Technische Dokumentation/Überschriften/1/Sicherheitshinweise @ 0\mod_1183637609261_6.doc @ 5365 9.1 Dryers dimensions 31 9.1.1 ACT 20 50 31 9.1.2 ACT 75 32 9.1.3 ACT 100 150 33 9.1.4 ACT 200 250 34 9.1.5 ACT 300 350 35 9.1.6 ACT 400 500 36 9.2 Exploded views 37 9.2.1 ACT 20 30 37 9.2.2 ACT 50 38 9.2.3 ACT 75 39 9.2.4 ACT 100 40 9.2.5 ACT 125 150 41 9.2.6 ACT 200 250 42 9.2.7 ACT 300 350 43 9.2.8 ACT 400 500 44 9.3 Electric diagrams 45 9.3.1 ACT 20 100 45 9.3.2 ACT 125 250 46 9.3.3 ACT 300 350 47 9.3.4 ACT 400 500 48 10 Blank pages 49 4 EN ACT 20 500 1ph

1 Identification plate Identification plate The identification plate is located on the back of the dryer and shows all the primary data of the machine. This data should always be referred to when calling the manufacturer or distributor. The removal or alteration of the identification plate will void the warranty rights. 2 Warranty conditions For 12 months from the installation date, but no longer than 14 months from the delivery date, the warranty covers eventual faulty parts, which will be repaired or replaced free of charge, except the travel, hotel and restaurant expenses of our engineer. The warranty doesn t cover any responsibility for direct or indirect damages to persons, animals or equipment caused by improper usage or maintenance, and it s limited to manufacturing faults only. The right to warranty repairs is subordinated to the strict compliance with the installation, use and maintenance instructions contained in this manual. The warranty will be immediately voided in case of even small changes or alterations to the dryer. To require repairs during the warranty period, the data reported on the identification plate must be notified. ACT 20 500 1ph 5 EN

3 Safety rules Safety rules 3.1 Definition of the conventional signs used in this manual Carefully read instruction manual before attempting any service or maintenance procedures on the dryer. Caution warning sign. Risk of danger or possibility of damage to equipment, if related text is not followed properly. Electrical hazard. Warning message indicates practices or procedures that could result in personal injury or fatality if not followed correctly. Danger hazard. Part or system under pressure. Danger hazard. High temperature conditions exist during operation of system. Avoid contact until system or component has dissipated heat. Danger hazard. Treated air is not suitable for breathing purposes; serious injury or fatality may result if precautions are not followed. Danger hazard: In case of fire, use an approved fire extinguisher, water is not an acceptable means in cases of fire. Danger hazard. Do not operate equipment with panels removed. Maintenance or control operation to be performed by qualified personnel only [1]. ARIA AIR LUFT AIR Compressed air inlet connection point ARIA AIR LUFT AIR Compressed air outlet connection point Condensate drain connection point Operations which can be performed by the operator of the machine, if qualified [1]. NOTE: Text that specifies items of note to be taken into account does not involve safety precautions. In designing this unit a lot of care has been devoted to environmental protection: CFC free refrigerants CFC free insulation parts Energy saving design Limited acoustic emission Dryer and relevant packaging composed of recyclable materials This symbol requests that the user heed environmental considerations and abide with suggestions annotated with this symbol. [1] Experienced and trained personnel familiar with national and local codes, capable to perform the needed activities, identify and avoid possible dangerous situations while handling, installing, using and servicing the machine. Ensuring compliance to all statutory regulations. 6 EN ACT 20 500 1ph

Safety rules 3.2 Warnings Compressed air is a highly hazardous energy source. Never work on the dryer with pressure in the system. Never point the compressed air or the condensate drain outlet hoses towards anybody. The user is responsible for the proper installation of the dryer. Failure to follow instructions given in the Installation chapter will void the warranty. Improper installation can create dangerous situations for personnel and/or damages to the machine could occur. Only qualified personnel are authorized to service electrically powered devices. Before attempting maintenance, the following conditions must be satisfied: Ensure that main power is off, machine is locked out, tagged for service and power cannot be restored during service operations. Ensure that valves are shut and the air circuit is at atmospheric pressure. De-pressurize the dryer. These refrigerating air dryers contain R134a or R407C HFC type refrigerant fluid. Refer to the specific paragraph - maintenance operation on the refrigerating circuit. Warranty does not apply to any unit damaged by accident, modification, misuse, negligence or misapplication. Unauthorized alterations will immediately void the warranty. In case of fire, use an approved fire extinguisher, water is not an acceptable means in cases of electrical fire. 3.3 Proper use of the dryer This dryer has been designed, manufactured and tested for the purpose of separating the humidity normally contained in compressed air. Any other use has to be considered improper. The Manufacturer will not be responsible for any problem arising from improper use; the user will bear responsibility for any resulting damage. Moreover, the correct use requires the adherence to the installation instructions, specifically: Voltage and frequency of the main power. Pressure, temperature and flow-rate of the inlet air. Ambient temperature. This dryer is supplied tested and fully assembled. The only operation left to the user is the connection to the plant in compliance with the instructions given in the following chapters. The purpose of the machine is the separation of water and eventual oil particles present in compressed air. The dried air cannot be used for breathing purposes or for operations leading to direct contact with foodstuff. This dryer is not suitable for the treatment of dirty air or of air containing solid particles. ACT 20 500 1ph 7 EN

Installation 3.4 Instructions for the use of pressure equipment according to PED directive 97/23/EC To ensure the safe operation of pressure equipments, the user must conform strictly to the above directive and the following: 1. The equipment must only be operated within the temperature and pressure limits stated on the manufacturer s data nameplate. 2. Welding on heat-exchanger is not recommended. 3. The equipment must not be stored in badly ventilated spaces, near a heat source or inflammable substances. 4. Vibration must be eliminated from the equipment to prevent fatigue failure. 5. Automatic condensate drains should be checked for operation every day to prevent a build up of condensate in the pressure equipment. 6. The maximum working pressure stated on the manufacturer s data nameplate must not be exceeded. Prior to use, the user must fit safety / pressure relief devices. 7. All documentation supplied with the equipment (manual, declaration of conformity etc.) must be kept for future reference. 8. Do not apply weights or external loads on the vessel or its connecting piping. 4 Installation TAMPERING, MODIFICATION AND IMPROPER USE OF THE PRESSURE EQUIPMENT ARE FORBIDDEN. Users of the equipment must comply with all local and national pressure equipment legislation in the country of installation. 4.1 Transport Check for visible loss or damage, if no visible damage is found place the unit near to the installation point and unpack the contents. To move the packaged unit we recommend using a suitable trolley or forklift truck. Hand carrying is not recommended. Always keep the dryer in the upright vertical position. Damage to components could result if unit is laid on its side or if placed upside down. Handle with care. Heavy blows could cause irreparable damage. 4.2 Storage Even when packaged, keep the machine protected from severity of the weather. Keep the dryer in vertical position, also when stored. Turning it upside down some parts could be irreparably damaged. If not in use, the dryer can be stored in its packaging in a dust free and protected site at a maximum temperature of 122 F (50 C), and a specific humidity not exceeding 90%. Should the stocking time exceed 12 months, please contact the manufacturer. SCC0001 The packaging materials are recyclable. Dispose of material in compliance with the rules and regulations in force in the destination country. 8 EN ACT 20 500 1ph

4.3 Installation site Installation Failure to install dryer in the proper ambient conditions will affect the dryer s ability to condense refrigerant gas. This can cause higher loads on the compressor, loss of dryer efficiency and performance, overheated condenser fan motors, electrical component failure and dryer failure due to the following: compressor loss, fan motor failure and electrical component failure. Failures of this type will affect warranty considerations. Do not install dryer in an environment of corrosive chemicals, explosive gasses, poisonous gasses; steam heat, areas of high ambient conditions or extreme dust and dirt. In case of fire, use an approved fire extinguisher, water is not an acceptable means in cases of fire. Minimum installation requirements: Select a clean dry area, free from dust, and protected from atmospheric disturbances. The supporting area must be smooth, horizontal and able to hold the weight of the dryer. Minimum ambient temperature +34 F (+1 C). Maximum ambient temperature +122 F (+50 C). Ensure a proper cooling air replacement. Allow a sufficient clearance on each side of the dryer for proper ventilation and to facilitate maintenance operations. The dryer does not require attachment to the floor surface. Do not block, even partially, ventilation grid. Avoid any possible re-circulation of the exhaust cooling air. Protect the dryer from air drafts or forced cooling air conditions. NOTE : Dryers models ACT 20 75 can be wall-mounted. See fixing dimensions on dimensional drawings in the attachment section. The hanging mounting inevitably causes the obstruction of the ventilation grid positioned on the panel facing the wall fixing. This obstruction, in any case, does not prejudge the efficiency of the ventilation inside the dryer which is guaranteed by other grids on the other panels. ACT 20 500 1ph 9 EN

Installation 4.4 Installation layout 1 Air compressor 2 Aftercooler 3 Condensate separator 4 Pre-Filter (min. 5 micron) 5 By-pass group 6 Dryer 7 Compressed air tank 8 Final filter 9 Condensate drain In case of heavily polluted inlet air (ISO 8573.1 class 3.-.3 or worse quality), we recommend the additional installation of a pre-filter (5 micron minimum) to prevent a clogging of the heat exchanger. Type A installation is suggested when the compressor operates at reduced intermittence and the total consumption equals the compressor flow rate. Type B installation is suggested when the air consumption can consistently change with peak values highly exceeding the flow rate of the compressors. The capacity of the tank must be sized in order to compensate eventual instantaneous demanding conditions (peak air consumption). 10 EN ACT 20 500 1ph

Installation 4.5 Correction factors Correction factor for operating pressure changes: Inlet air pressure psig 60 80 100 120 140 160 180 203 barg 4 5.5 7 8 10 11 12 14 Factor (F1) 0.79 0.91 1.00 1.07 1.13 1.18 1.23 1.27 Correction factor for ambient temperature changes : Ambient temperature ºF 80 90 95 100 105 110 115 122 ºC 27 32 35 38 40 43 45 50 Factor (F2) 1.11 1.09 1.06 1.00 0.94 0.87 0.78 0.69 Correction factor for inlet air temperature changes: Air temperature ºF 90 100 110 122 130 140 150 158 ºC 32 38 43 50 55 60 65 70 Factor (F3) 1.16 1.00 0.82 0.68 0.61 0.52 0.45 0.40 Correction factor for DewPoint changes: DewPoint ºF 38 41 45 50 ºC 3 5 7 10 Factor (F4) 1.00 1.08 1.20 1.36 How to find the air flow capacity: Air flow capacity = Nominal duty x Factor (F1) x Factor (F2) x Factor (F3) x Factor (F4) Example: An ACT 75 has a nominal duty of 75 scfm (127 m³/h). What is the maximum allowable flow through the dryer under the following operating conditions: Inlet air pressure = 120 psig (8 barg) Ambient temperature = 115 F (45 C) Inlet air temperature = 122 F (50 C) Pressure DewPoint = 50 F (10 C) Factor (F1) = 1.07 Factor (F2) = 0.78 Factor (F3) = 0.68 Factor (F4) = 1.36 Each item of data has a corresponding numerical factor which multiplied by the design air flow is as follows: Air flow capacity = 75 x 1.07 x 0.78 x 0.68 x 1.36 = 58 scfm (99 m³/h) 58 scfm (99 m³/h) This is the maximum flow rate that the dryer can accept under these operating conditions. How to select a suitable dryer for a given duty: Design air flow Minimum std. air flow rate = Factor (F1) x Factor (F2) x Factor (F3) x Factor (F4) Example: With the following operating parameters: Design air flow = 100 scfm (170 m 3 /h) Inlet air pressure = 120 psig (8 barg) Ambient temperature = 115 F (45 C) Inlet air temperature = 122 F (50 C) Pressure DewPoint = 50 F (10 C) Factor (F1) = 1.07 Factor (F2) = 0.78 Factor (F3) = 0.68 Factor (F4) = 1.36 In order to select the correct dryer model the required flow rate is to be divided by the correction factors relating to above mentioned parameters: 100 Minimum std. air flow rate = = 130 scfm (221 m³/h) 1.07 x 0.78 x 0.68 x 1.36 Therefore the model suitable for the conditions above is ACT 150 (150 scfm [255 m³/h] - nominal duty). ACT 20 500 1ph 11 EN

4.6 Connection to the compressed air system Installation Operations to be performed by qualified personnel only. Never work on system under pressure. The user is responsible to ensure that the dryer will never be operated with pressure exceeding the maximum pressure rating on the unit data tag. Over-pressurizing the dryer could be dangerous for both the operator and the unit. The air temperature and the flow entering the dryer must comply within the limits stated on the data nameplate. The system connecting piping must be kept free from dust, rust, chips and other impurities, and must be consistent with the flow-rate of the dryer. In case of treatment of air at particularly high temperature, the installation of a final refrigerator could result necessary. In order to perform maintenance operations, it is recommended to install a dryer by-pass system. In case of heavily polluted inlet air (ISO 8573.1 class 3.-.3 or worse quality), we recommend the additional installation of a pre-filter (5 micron minimum) to prevent a clogging of the heat exchanger. In realising the dryer, particular measures have been taken in order to limit the vibration which could occur during the operation. Therefore we recommend to use connecting pipes able to insulate the dryer from possible vibrations originating from the line (flexible hoses, vibration damping fittings, etc.). CAUTION : PIPING THE DRYER, INLET/OUTLET CONNECTIONS MUST BE SUPPORTED AS SHOWN IN THE DIAGRAM. FAILING WILL RESULT IN DAMAGE. 4.7 Electrical connections Qualified personnel should carry out connecting unit to the main power. Be sure to check the local codes in your area. Before connecting the unit to the electrical supply, verify the data nameplate for the proper electrical information. Voltage tolerance is +/- 10%. Dryer are supplied with power cord and plug. Be sure to provide the proper fuses or breakers based on the data information located on the nameplate. A residual-current device (RCD) with I n =0.03A is suggested. The cross section of the power supply cables must comply with the consumption of the dryer, while keeping into account also the ambient temperature, the conditions of the mains installation, the length of the cables, and the requirements enforced by the local Power Provider. Important: ensure that the dryer is earthed. Do not use any socket adapters at the mains plug. If the mains plug needs to be replaced, this must only be done by a qualified electrician. 4.8 Condensate drain The condensate is discharge at the system pressure. Drain line should be secured. Never point the condensate drain line towards anybody. The dryer comes already fitted with a timed condensate drainer (solenoid valve controlled by electronic instrument) or with an electronic condensate drainer (optional). Connect and properly fasten the condensate drain to a collecting plant or container. The drain cannot be connected to pressurized systems. Don t dispose the condensate in the environment. The condensate collected in the dryer contains oil particles released in the air by the compressor. Dispose the condensate in compliance with the local rules. We recommend to install a water-oil separator where to convey all the condensate drain coming from compressors, dryers, tanks, filters, etc. 12 EN ACT 20 500 1ph

5 Start-up Start-up 5.1 Preliminary operation Verify that the operating parameters match with the nominal values stated on the data nameplate of the dryer (voltage, frequency, air pressure, air temperature, ambient temperature, etc.). This dryer has been thoroughly tested, packaged and inspected prior to shipment. Nevertheless, the unit could be damaged during transportation, check the integrity of the dryer during first start-up and monitor operation during the first hours of operation. Qualified personnel must perform the first start-up. When installing and operating this equipment, comply with all National Electrical Code and any applicable federal, state and local codes. Who is operating the unit is responsible for the proper and safe operation of the dryer. Never operate equipment with panels removed. 5.2 First start-up This procedure should be followed on first start-up, after periods of extended shutdown or following maintenance procedures.qualified personnel must perform the start-up. Sequence of operations (refer to paragraph 7.1 Control Panel). Ensure that all the steps of the Installation chapter have been observed. Ensure that the connection to the compressed air system is correct and that the piping is suitably fixed and supported. Ensure that the condensate drain pipe is properly fastened and connected to a collection system or container. Ensure that the by-pass system (if installed) is closed and the dryer is isolated. Ensure that the manual valve of the condensate drain circuit is open. Remove any packaging and other material which could obstruct the area around the dryer. Activate the mains switch. Turn ON the switch - pos. 1 on the control panel. Ensure that electronic instrument is ON. Ensure the consumption matches with the values of the data plate. Ensure the fan works properly wait for its first interventions. Allow the dryer temperature to stabilise at the pre-set value. Slowly open the air inlet valve. Slowly open the air outlet valve. Slowly close the central by-pass valve of the system (if installed). Check the piping for air leakage. Ensure the drain is regularly cycling - wait for its first interventions. ACT 20 500 1ph 13 EN

Start-up 5.3 Start-up and shut down Start-up (refer to paragraph 7.1 Control Panel) Check the condenser for cleanliness. Turn ON the switch - pos. 1 on the control panel. Ensure that electronic instrument is ON. Wait a few minutes; verify that the DewPoint temperature displayed on electronic instrument is correct and that the condensate is regularly drained. Switch on the air compressor. Shut down (refer to paragraph 7.1 Control Panel) Check that the DewPoint temperature indicated on the electronic instrument is within range. Shut down the air compressor. After a few minutes, turn OFF the switch - pos. 1 on the control panel. NOTE : A DewPoint within 32 F (0 C) and +50 F (+10 C) displayed on electronic instrument is correct according to the possible working conditions (flow-rate, temperature of the incoming air, ambient temperature, etc.). During the operation, the refrigerant compressor will run continuously. The dryer must remain on during the full usage period of the compressed air, even if the air compressor works intermittently. The number of starts must be no more than 6 per hour. The dryer must stop running for at least 5 minutes before being started up again. Frequent starts may cause irreparable damage. The user is responsible for compliance with these rules. 14 EN ACT 20 500 1ph

6 Technical data Technical data 6.1 Technical data ACT 20 200 1/115/60 ACT 20 500 1ph 15 EN

6.2 Technical data ACT 125 500 1/230/60 Technical data 16 EN ACT 20 500 1ph

7 Technical description Technical description 7.1 Control panel The control panel illustrated below is the only dryer-operator interface. ACT 20 100 K 1 0 PQS0051 1 Set 2 3 ACT 125 500 I ON K Set PQS0052 1 2 3 1 2 3 ON-OFF Switch Electronic instrument Air and refrigerant flow diagram 7.2 Operation Operating principle - The dryer models described in this manual operate all on the same principle. The hot moisture laden air enters an air to air heat exchanger. The air then goes through the evaporator, also known as the air to refrigerant heat exchanger. The temperature of the air is reduced to approximately 36 F (2 C), causing water vapor to condense to liquid. The liquid is continuously coalesced and collected in the separator for removal by the condensate drain. The cool moisture free air then passes back through the air to air heat exchanger to be reheated to within 8 degrees of the incoming air temperature as it exits the dryer. Refrigerant circuit - Refrigerant gas is cycled through the compressor and exits at high pressure to a condenser where heat is removed causing the refrigerant to condense to a high-pressure liquid state. The liquid is forced through a capillary tube where the resulting pressure drop allows the refrigerant to boil off at a predetermined temperature. Low-pressure liquid refrigerant enters the heat exchanger where heat from the incoming air is transferred causing the refrigerant to boil; the resulting phase change produces a low pressure, low temperature gas. The low-pressure gas is returned to the compressor, where it is recompressed and begins the cycle again. During those periods when the compressed air load is reduced the excess refrigerant is by-passed automatically back to the compressor via the hot gas by-pass valve circuit. ACT 20 500 1ph 17 EN

Technical description 7.3 Flow diagram 2 3 4 5 P< TS P> PV 6 1a 25 7 1 1b 9 M 8 12 1c T1 11 10 DGF0071 14 15 13 Standard 16 21 ELD EC 17 Option 1 Alu-Dry module 9 Condenser fan 1a Air-to-air heat exchanger 10 Filter dryer 1b Air-to-refrigerant heat exchanger 11 Capillary tube 1c Condensate separator 12 Temperature probe T1 DewPoint 2 Refrigerant pressure switch LPS (ACT 300-500) 13 Condensate drain service valve 3 Safety thermo switch TS (ACT 125-500) 14 Condensate drain strainer 4 Refrigerant pressure switch HPS (ACT 300-500) 15 Condensate drain solenoid valve 5 Refrigerant pressure switch PV 16 Coil for condensate drain solenoid valve 6 Compressor 17 Electronic instrument 7 Hot gas by-pass valve 21 Electronic drainer 8 Condenser 25 Not used Compressed air flow direction Refrigerant gas flow direction 18 EN ACT 20 500 1ph

Technical description 7.4 Refrigerating compressor The refrigerating compressor is the pump in the system, gas coming from the evaporator (low pressure side) is compressed up to the condensation pressure (high pressure side). The compressors utilized are manufactured by leading manufacturers and are designed for applications where high compression ratios and wide temperature changes are present. The hermetically sealed construction is perfectly gas tight, ensuring high-energy efficiency and long, useful life. Dumping springs support the pumping unit in order to reduce the acoustic emission and the vibration diffusion. The aspirated refrigerant gas, flowing through the coils before reaching the compression cylinders cools the electric motor. The thermal protection protects the compressor from over heating and over currents. The protection is automatically restored as soon as the nominal temperature conditions are reached. 7.5 Condenser The condenser is the component in which the gas coming from the compressor is cooled down and condensed becoming a liquid. Mechanically, a serpentine copper tubing circuit (with the gas flowing inside) is encapsulated in an aluminum fin package. The cooling operation occurs via a high efficiency fan, creating airflow within the dryer, moving air through the fin package. It s mandatory that the ambient air temperature does not exceed the nominal values. It is also important to keep the condenser unit free from dust and other impurities. 7.6 Filter dryer Traces of humidity and slag can accumulate inside the refrigerant circuit. Long periods of use can also produce sludge. This can limit the lubrication efficiency of the compressor and clog the expansion valve or capillary tube. The function of the filter drier, located before the capillary tubing, is to eliminate any impurities from circulating through the system. 7.7 Capillary tube It consists of a piece of reduced cross section copper tubing located between the condenser and the evaporator, acting as a metering device to reduce the pressure of the refrigerant. Reduction of pressure is a design function to achieve optimum temperature reached within the evaporator: the smaller the capillary tube outlet pressure, the lower the evaporation temperature. The length and interior diameter of the capillary tubing is accurately sized to establish the performance of the dryer; no maintenance or adjustment is necessary. 7.8 Alu-Dry module The heat exchanger module houses the air-to-air, the air-to-refrigerant heat exchangers and the demister type condensate separator. The counter flow of compressed air in the air-to-air heat exchanger ensures maximum heat transfer. The generous cross section of flow channel within the heat exchanger module leads to low velocities and reduced power requirements. The generous dimensions of the air-to-refrigerant heat exchanger plus the counter flow gas flow allows full and complete evaporation of the refrigerant (preventing liquid return to the compressor). The high efficiency condensate separator is located within the heat exchanger module. No maintenance is required and the coalescing effect results in a high degree of moisture separation. ACT 20 500 1ph 19 EN

7.9 Hot gas by-pass valve Technical description This valve injects part of the hot gas (taken from the discharge side of the compressor) in the pipe between the evaporator and the suction side of the compressor, keeping the evaporation temperature/pressure constant at approx. +36 F (+2 C). This injection prevents the formation of ice inside the dryer evaporator at every load condition. ADJUSTMENT The hot gas by-pass valve is adjusted during the manufacturing testing phase. As a rule no adjustment is required; anyway if it is necessary the operation must be carried out by an experienced refrigerating engineer. WARNING the use of ¼ Schrader service valves must be justified by a real malfunction of the refrigerating system. Each time a pressure gauge is connected, a part of refrigerant is exhausted. Without compressed air flow through the dryer, rotate the adjusting screw (position A on the drawing) until the following value is reached: Hot gas setting : R134.a pressure 29.0 psig (+ 1.45 / -0 psi) [2.0 barg (+0.1 / -0 bar)] R407C pressure 65.3 psig (+1.45 / -0 psi) [4.5 barg (+0.1 / -0 bar)] 7.10 Refrigerant pressure switches LPS HPS PV As operation safety and protection of the dryer a series of pressure switches are installed in the gas circuit. LPS : Low-pressure protection device on the suction side of the compressor, trips if the pressure drops below the pre-set value. The values are automatically reset when the nominal conditions are restored. Calibrated pressure : R 134.a Stop 10.2 psig (0.7 barg) - Restart 24.7 psig (1.7 barg) R 407 C Stop 24.7 psig (1.7 barg) - Restart 39.2 psig (2.7 barg) HPS : This high-pressure controller device, located on the discharge side on the compressor, is activated when the pressure exceeds the pre-set value. It features a manual-resetting button mounted on the PV : controller itself. Calibrated pressure : VLY0001 - + A 4 mm 5/32 in. R 134.a Stop 290 psig (20 barg) - Manual reset P<203 psi (P<14 bar) R 407 C Stop 435 psig (30 barg) - Manual reset P<334 psi (P<23 bar) Fan control pressure switch located at the discharge side of compressor. It keeps the condensing temperature/pressure constant within preset limits. Calibrated pressure : R 134.a Start 160 psig (+7.25 / -0 psi) [11 barg (+0.5 / -0 bar)] Stop 116 psig (+0 / -7.25 psi) [8 barg (+0 / -0.5 bar)] R 407 C Start 261 psig (+7.25 / -0 psi) [18 barg (+0.5 / -0 bar)] Stop 203 psig (+0 / -7.25 psi) [14 barg (+0 / -0.5 bar)] 7.11 Safety thermo switch TS PQS0005 1 2 To protect the operating safety and the integrity of the dryer, a thermo switch (TS) is installed on the refrigerant gas circuit. The thermo switch sensor, in case of unusual discharge temperatures, stops the refrigerating compressor before it is permanently damaged. Manually reset the thermo switch only after the nominal operating conditions have been restored. Unscrew the relative cap (see pos.1 in the figure) and press the reset button (see pos.2 in the figure). TS setting : temperature 235,4 F (113 C) (+0 / -6 K) 20 EN ACT 20 500 1ph

Technical description 7.12 Electronic instrument DMC14 Led - Temperature in C Led - Temperature in F Led Drain ON Led Alarm/Service PQS0050 Set Set Button Setup menu access Button Decrease DISPLAY Button Increase / Drain test The DMC14 controls the alarms and the settings of the dryer operations and th timed drainer. 7.12.1 How to switch on the dryer Power the dryer and switch it on using the ON-OFF switch (pos. 1 paragraph 7.1). During normal operation the display shows the DewPoint temperature. The condensate drain test is always active using the button. 7.12.2 How to switch off the dryer Switch it off using the ON-OFF switch (pos. 1 paragraph 7.1). 7.12.3 How to display the operating parameters During normal operation, the display shows the DewPoint temperature (in C or F). Press and hold Set button to display parameter (alarm tripping temperature for high dewpoint). NOTE : The temperatures are displayed in C or F (led or is lighted). 7.12.4 How a service warning / alarm is displayed A service warning / alarm is an unusual event that must recall the attention of the operators/maintenance technicians. It does not stop the dryer. When a service warning / alarm is active, the led is lighted or flashing. Service warnings / alarms are automatically reset as soon as the problem is solved. NOTE: the operator/maintenance technician must inspect the dryer and verify/solve the problem that generated the service warning. Service Warning / Alarm Description lighted + on display PF - Probe Failure : failure temperature probe flashing + high temperature on display flashing + low temperature on display High DewPoint: DewPoint too high, higher than the value set (delay ). Alarm disappears when temperature drop 0.5 C / 1 F below the alarm set point Low DewPoint : DewPoint too low, lower than -2.0 C / 28 F (delay 30 seconds). Alarm disappears when temperature becomes higher than -0.5 C / 31 F. ACT 20 500 1ph 21 EN

Technical description 7.12.5 How is controlled the drain solenoid valve Drain solenoid valve is activated (ON) for seconds (standard 2 seconds) every minutes (standard 1 minute). Led shows that condensate drain solenoid valve is ON. The condensate drain test is always active using the button. 7.12.6 Operation of the failure / alarm dry contact The DMC14 is equipped with a dry contact (potential free) to display failure and/or alarm conditions. 8 9 Dryer powered and no service warning / alarm is active. 8 9 Dryer not powered or service warning / alarm is active. 7.12.7 How to change the operating parameters SETUP menu The setup menu can be used to change the dryer s operating parameters. Only qualified personnel must be allowed to access to the setup menu. The manufacturer is not responsible for malfunctioning or failure due to modification to the operating parameters. With dryer ON simultaneously press buttons Set + for at least 3 seconds to enter the setup menu. Access to the menu is confirmed by message on the display (first parameter of menu). Keep Set pressed to display the value of the selected parameter and use arrows and to change the value. Release the button Set to confirm the value and skip to following parameter. Press + to exit setup menu (if no button is pressed after 10 seconds the menu is exited automatically). ID Description Limits Resolution Standard setup Ton drain time ON : time ON condensate drain valve 00 20 sec 1 sec 2 ToF - drain time OFF : pause time for condensate drain valve 1 20 min 1 min 1 ASH High DewPoint Setting : Alarm threshold for a high DewPoint (the alarm disappears when the temperature drop 0.5 C / 1 F below alarm point) 0.0 25.0 C or 32 77 F 0.5 C or 1 F 20 or 68 AdH - High DewPoint Delay : high DewPoint alarm enable delay 01 20 minutes 1 min 15 SCL - Scale: display scale of temperatures. C F - F 22 EN ACT 20 500 1ph

Technical description 7.13 Electronic drainer (optional) Instead of the usual drain system (a solenoid valve controlled by means of electronic instrument); an electronic level controlled drainer can be installed as option. This drainer consists of a condensate accumulator where a capacitive sensor continuously checking liquid level is placed: as soon as the accumulator is filled, the sensor passes a signal to the electronic control and a diaphragm solenoid valve will open to discharge the condensate. For a complete condensate discharge the valve opening time will be adjusted exactly for each single drain operation. No condensate strainers are installed. No adjusting is required. A service valve is installed before the electronic drain in order to make check and maintenance easily. At dryer start-up verify that this valve is open. Control panel for dryers ACT 20 350 Power / Service Led TEST Button Green ON - ready to work / supplied Green blinking maintenance required Orange ON Circuit board defect Discharge test (keep pushed for 2 seconds) Control panel for dryers ACT 400 500 Power / Service Led (green) Alarm Led (red) Power+Alarm Led TEST Button ON - ready to work / supplied Blinking maintenance required Blinking alarm condition ON - circuit board defect Discharge test (keep pushed for 2 seconds) Troubleshooting Only qualified personnel should perform troubleshooting and or maintenance operations. Prior to performing any maintenance or service, be sure that : no part of the machine is powered and that it cannot be connected to the mains supply. no part of the machine is under pressure and that it cannot be connected to the compressed air system. maintenance personnel have read and understand the safety and operation instructions in this manual. PLEASE REFER TO INSTRUCTION MANUAL OF ELECTRONIC DRAINER ACT 20 500 1ph 23 EN

Maintenance, troubleshooting, spare parts and dismantling 8 Maintenance, troubleshooting, spare parts and dismantling 8.1 Checks and maintenance Only qualified personnel should perform troubleshooting and or maintenance operations. Prior to performing any maintenance or service, be sure that : no part of the machine is powered and that it cannot be connected to the mains supply. no part of the machine is under pressure and that it cannot be connected to the compressed air system. maintenance personnel have read and understand the safety and operation instructions in this manual. Before attempting any maintenance operation on the dryer, shut it down and wait at least 30 minutes. Some components can reach high temperature during operation. Avoid contact until system or component has dissipated heat. Daily Verify that the DewPoint displayed on the electronic instrument is correct. Check the proper operation of the condensate drain systems. Verify the condenser for cleanliness. Every 200 hours or monthly With an air jet (max. 2 bar / 30 psig) blowing from inside towards outside clean the condenser; repeat this operation blowing in the opposite way; be careful not to damage the aluminum fins of the cooling package. Close the manual condensate drain valve, unscrew the strainer (if installed) and clean it with compressed air and brush. Reinstall the strainer properly tight, and then open the manual valve. At the end, check the operation of the machine Every 1000 hours or yearly Verify for tightness all the screws of the electric system and that all the Disconnects-Tabs type connections are in their proper position inspect unit for broken, cracked or bare wires. Inspect refrigerating circuit for signs of oil and refrigerant leakage. Measure and record amperage. Verify that readings are within acceptable parameters as listed in specification table. Inspect flexible hoses, and replace if necessary. At the end, check the operation of the machine. Every 8000 hours Replace Electronic drainer service unit 24 EN ACT 20 500 1ph

8.2 Troubleshooting Maintenance, troubleshooting, spare parts and dismantling Only qualified personnel should perform troubleshooting and or maintenance operations. Prior to performing any maintenance or service, be sure that : no part of the machine is powered and that it cannot be connected to the mains supply. no part of the machine is under pressure and that it cannot be connected to the compressed air system. maintenance personnel have read and understand the safety and operation instructions in this manual. Before attempting any maintenance operation on the dryer, shut it down and wait at least 30 minutes. Some components can reach high temperature during operation. Avoid contact until system or component has dissipated heat. SYMPTOM The dryer doesn't start. The compressor doesn t work. Condenser s fan doesn t work. DewPoint too high. Dew Point too low Verify that the system is powered. Verify the electric wiring. POSSIBLE CAUSE - SUGGESTED ACTION Activation of the compressor internal thermal protection - wait for 30 minutes, then retry. Verify the electric wiring. If installed - Replace the internal thermal protection and/or the start-up relay and/or the start-up capacitor and/or the working capacitor. If installed - The pressure switch HPS has been activated - see specific point. If installed - The pressure switch LPS has been activated - see specific point. If installed - The safety thermo switch TS has been activated - see specific point If the compressor still doesn t work, replace it. Verify the electric wiring. PV pressure switch is faulty replace it There is a leak in the refrigerant circuit - contact a refrigeration engineer. If the fan still doesn't work, replace it. The dryer doesn't start - see specific point. The DewPoint probe T1 doesn t correctly detect the temperature - ensure the sensor is pushed into the bottom of probe well. The Compressor doesn t work - see specific point. The ambient temperature is too high or the room aeration is insufficient - provide proper ventilation. The inlet air is too hot - restore nominal conditions. The inlet air pressure is too low - restore nominal conditions. The inlet air flow rate is higher than the rate of the dryer - reduce the flow rate - restore nominal conditions. The condenser is dirty - clean it. The condenser fan doesn t work - see specific point. The dryer doesn t drain the condensate - see specific point. The hot gas by-pass valve is out of setting - contact a refrigeration engineer to restore nominal setting. There is a leak in the refrigerant circuit - contact a refrigeration engineer. The fan is always on PV pressure switch is faulty replace it. Ambient temperature is too low - restore nominal conditions. The hot gas by-pass valve is out of setting - contact a refrigeration engineer to restore nominal setting. ACT 20 500 1ph 25 EN

Maintenance, troubleshooting, spare parts and dismantling SYMPTOM Excessive pressure drop within the dryer. The dryer doesn t drain the condensate The dryer continuously drains condensate. Water within the line. If installed HPS high pressure switch has been activated. If installed LPS low pressure switch has been activated. If installed TS safety thermo switch has been activated. Electronic instrument DMC14 The led is on or flashes. POSSIBLE CAUSE - SUGGESTED ACTION The dryer doesn t drain the condensate - see specific point. The DewPoint is too low - the condensate is frost and blocks the air - see specific point. Check for throttling the flexible connection hoses. The condensate drain service valve is closed - open it. Condensate strainer is clogged remove and clean it. The drain solenoid valve is jammed remove and clean it. Verify the electric wiring. The coil of the drain solenoid valve is failed replace it. Electronic instrument is faulty repace it. The DewPoint is too low - the condensate is frost and blocks the air - see specific point. Inlet compressed air pressure is too low and condensate is not drained restore nominal conditions. Electronic drainer is not operating correctly (see paragraph 7.13). The drain solenoid valve is jammed remove and clean it. Try to remove the electric connector on the solenoid valve - if drain stops verify the electric wiring or the electronic instrument is faulty - replace it Electronic drainer is dirty (see paragraph 7.13). The dryer doesn't start - see specific point. If installed - Untreated air flows through the by-pass unit - close the by-pass. The dryer doesn t drain the condensate - see specific point. DewPoint too high - see specific point. Check which of the following has caused the activation : 1. The ambient temperature is too high or the room aeration is insufficient - provide proper ventilation. 2. The condenser is dirty - clean it. 3. The condenser fan doesn t work - see specific point. Reset the pressure switch pressing the button on the controller itself - verify the dryer for correct operation. HPS pressure switch is faulty - contact a refrigeration engineer to replace it. There is a leak in the refrigerating fluid circuit - contact a refrigeration engineer. The pressure switch reset automatically when normal conditions are restored - check the proper operation of the dryer. Check which of the following has caused the activation : 1. Eccessive thermal load restore the standard operating conditions. 2. The inlet air is too hot - restore the nominal conditions. 3. The ambient temperature is too high or the room aeration is insufficient - provide proper ventilation. 4. The condenser unit is dirty - clean it. 5. The fan doesn t work - see specific point. 6. The hot gas by-pass valve requires re-adjusting contact a specialized technician to restore nominal setting. 7. Refrigerant gas leak - contact a refrigeration engineer. Reset the thermo switch by pressing the button on the thermo switch itself verify the correct operation of the dryer. TS thermo switch is faulty - replace it. The led The led flashes because the DewPoint is too high see specific point. flashes because the DewPoint is too low - see specific point. The led is on because the probe is faulty or interrupted, the instrument displays the message PF (Probe Failure) replace the probe. 26 EN ACT 20 500 1ph

8.3 Spare parts Maintenance, troubleshooting, spare parts and dismantling The suggested spare parts list will enable you to promptly intervene in case of abnormal operation, so avoiding to wait for the spares delivery. In case of failure of other parts, for example inside the refrigerating circuit, the replacement must be worked out by a refrigerating systems specialist or in our factory. NOTE: To order the suggested spare parts or any other part, it s necessary to quote the data reported on the identification plate. ACT 20 500 1ph 27 EN

Maintenance, troubleshooting, spare parts and dismantling 28 EN ACT 20 500 1ph

Maintenance, troubleshooting, spare parts and dismantling 8.4 Maintenance operation on the refrigeration circuit Maintenance and service on refrigerating systems must be carried out only by certified refrigerating engineers only, according to local rules. All the refrigerant of the system must be recovered for its recycling, reclamation or destruction. Do not dispose the refrigerant fluid in the environment. This dryer comes ready to operate and filled with R134a or R407C type refrigerant fluid. In case of refrigerant leak contact a certified refrigerating engineer. Room is to be aired before any intervention. If is required to re-fill the refrigerating circuit, contact a certified refrigerating engineers. Refer to the dryer nameplate for refrigerant type and quantity. Characteristics of refrigerants used: Refrigerant Chemical formula TLV GWP R134a - HFC CH2FCF3 1000 ppm 1300 R407C - HFC R32/125/134a (23/25/52) CHF2CF3/CH2F2/CH2FCF3 1000 ppm 1653 8.5 Dismantling of the dryer If the dryer is to be dismantled, it has to be split into homogeneous groups of materials. Part Refrigerant fluid Canopy and Supports Refrigerating compressor Alu-Dry Module Condenser Unit Pipe Fan Valve Electronic Level Drain Insulation Material Electric cable Electric Parts Material R407C, R134a, Oil Carbon steel, Epoxy paint Steel, Copper, Aluminium, Oil Aluminium Aluminium, Copper, Carbon steel Copper Aluminium, Copper, Steel Brass, Steel PVC, Aluminium, Steel Synthetic rubber without CFC, Polystyrene, Polyurethane Copper, PVC PVC, Copper, Brass We recommend to comply with the safety rules in force for the disposal of each type of material. Refrigerant contains droplets of lubrication oil released by the refrigerating compressor. Do not dispose this fluid in the environment. Is has to be discharged from the dryer with a suitable device and then delivered to a collection centre where it will be processed to make it reusable. ACT 20 500 1ph 29 EN

9 Attachments Exploded views List of components Attachments 1 Alu-Dry module 16 Coil for condensate drain solenoid valve 1.1 Insulation material 17 Electronic instrument 2 Refrigerant pressure switch LPS 21 Electronic drainer 3 Safety thermo switch TS 22 Main switch 4 Refrigerant pressure switch HPS 51 Front panel 5 Refrigerant pressure switch PV 52 Back panel 6 Compressor 53 Right lateral panel 7 Hot-gas bypass valve 54 Left lateral panel 8 Condenser 55 Cover 9 Condenser fan 56 Base plate 9.1 Motor 57 Upper plate 9.2 Blade 58 Support beam 9.3 Grid 59 Support bracket 10 Filter dryer 60 Control panel 11 Capillary tube 61 Electric connecting plug 12 Temperature probe 66 QE door 13 Condensate drain service valve 81 Flow diagram sticker 14 Condensate drain strainer 83 Refrigerant service valve - high pressure 15 Condensate drain solenoid valve 84 Refrigerant service valve - low pressure Electric diagrams List of components MC1 Compressor BT1 Temperature probe KT Compressor thermal protection LPS Low pressure switch KR Compressor starting relay HPS High pressure switch CS Compressor starting capacitor PV Pressure switch fan control CR Compressor operating capacitor TS Safety thermo switch MV1 Condenser fan EVD Timed condensate drain solenoid valve KV Fan thermal protection ELD Electronic drainer CV Fan starting capacitor S1 ON-OFF switch DMC14 Electronic instrument NT4 Provided and wired by customer NT5 Limit of equipment BN Brown OR Orange BU Blue RD Red BK Black WH White YG Yellow / Green WH/BK White / Black 30 EN ACT 20 500 1ph

Attachments 9.1 Dryers dimensions 9.1.1 ACT 20 50 ACT 20 500 1ph 31 EN